URAL Motorcycles

URAL Motorcycles
Owner’s Manual
2003 Model
Retro Solo
Irbit Motorworks of America Inc.
7943 159th PL. NE
Redmond Wa.
98052
www.imz-ural.com
Contents
Introduction ............................................................................................................................................................. 5
Warnings, Cautions, Notes ....................................................................................................................................... 5
Chapter 1 Specifications
Specifications .......................................................................................................................................................... 7
Torque Specifications ............................................................................................................................................. 10
Conversions .......................................................................................................................................................... 10
Chapter 2 Motorcycle Controls & Instrumentation
Motorcycle Controls & Instrumentation ................................................................................................................... 11
Controls ................................................................................................................................................................ 12
Control Cable Adjustment ...................................................................................................................................... 16
Control Cable Maintenance ................................................................................................................................... 16
Speedometer ......................................................................................................................................................... 16
Chapter 3 Engine Operation
Engine Operation and Maintenance ........................................................................................................................
Pre-Trip Preliminaries ............................................................................................................................................
Starting the Engine .................................................................................................................................................
Operating Precautions ............................................................................................................................................
Running-In the New Motorcycle ............................................................................................................................
17
17
17
21
21
Chapter 4 Engine Design
Brief Description of Design & Maintenance ..........................................................................................................
Lubrication System ................................................................................................................................................
Fuel System ...........................................................................................................................................................
Ignition System ......................................................................................................................................................
Ignition Timing .......................................................................................................................................................
23
24
25
26
26
Chapter 5 Carburetors
Carburetors ........................................................................................................................................................... 29
Carburetor Maintenance ........................................................................................................................................ 30
Chapter 6 Power Transmission
Power Transmission ...............................................................................................................................................
Clutch ...................................................................................................................................................................
Gearbox ................................................................................................................................................................
Final Drive .............................................................................................................................................................
31
31
31
31
Chapter 7 Running Gear
Running Gear .........................................................................................................................................................
Spring-Loaded Hydrraulic Shock Absorber ...........................................................................................................
Front Fork ............................................................................................................................................................
Steering Head Bearings ..........................................................................................................................................
33
33
34
34
Chapter 8 Wheel & Tires
Wheels and Tires ................................................................................................................................................... 35
Tire Data ................................................................................................................................................................36
Wheel and Tire Maintenance ................................................................................................................................. 37
Chapter 9 Brakes
Brakes .................................................................................................................................................................. 39
Chapter 10 Electrical
Electrical Equipment .............................................................................................................................................. 43
Electrical Circuits.....................................................................................................................................................43
Electrical Equipment Maintenance .......................................................................................................................... 44
Electrical Wiring Diagram ....................................................................................................................................... 46
Chapter 11 Maintenance
Maintenance of Motorcycle ...................................................................................................................................
List of Recommended Lubricants ...........................................................................................................................
Lubrication Chart ...................................................................................................................................................
Required Lubrication .............................................................................................................................................
Care of Motorcycle Paint .......................................................................................................................................
Preservation and Storage .......................................................................................................................................
Battery ..................................................................................................................................................................
List of Individual Tool Set, Spare Parts, Accessories & Documents .........................................................................
47
47
48
48
48
49
50
51
Chapter 12 Safe Operating Rules
Safe Operating Rules ............................................................................................................................................. 53
Chapter 13 Warranty
Warranty Agreement ............................................................................................................................................. 55
Warranty Claim Form ........................................................................................................................................... 63
Flat Rate Schedule ............................................................................................................................................... 64
Chapter 14 Service Coupons
Service Coupons ................................................................................................................................................... 67
New Address Form ............................................................................................................................................... 77
New Owner Form ................................................................................................................................................. 78
URAL Starting and Running Tips .................................................................................................... Inside Back Cover
4
INTRODUCTION
Welcome to the URAL Motorcycling Family! Your Ural has been built by the Irbit Motorcycle Factory in
Russia and distributed by Irbit Motorworks of America, the United States affiliate of the Irbit Motorcycle
Factory. The Ural motorcycle conforms to all applicable US Federal Motor Vehicle Safety Standards and
US Environmental Protection Agency regulations effective on the date of manufacture.
This manual has been prepared to acquaint you with the operation, care and maintenance of your
motorcycle, and to provide you with important safety information. Follow these instructions carefully for
maximum motorcycle performance and for your personal motorcycling safety and pleasure.
Your Owner’s Manual contains instructions for operation, maintenance and minor repairs. Major repairs
require the attention of a skilled mechanic and the use of special tools and equipment. Your Authorized
IMWA Ural Dealer has the facilities, experience and genuine Ural parts necessary to provide this
valuable service.
Any suggestions or comments are welcome! Write to us or post an e-mail on the Ural Discussion
bulletin board at www.imz-ural.com.
Happy Riding!
Important Notice!
Statements in this manual preceded by the following words are of special importance:
WARNING:
MEANS THERE IS THE POSSIBILITY OF PERSONAL
YOURSELF OR OTHERS.
CAUTION:
Means there is the possibility of damage to the vehicle.
NOTE:
Other information of particular importance has been placed in
italic type.
INJURY TO
CAUTION! During the initial 1,500 km, a fundamental bedding-in of parts for all the mechanisms
of the motorcycle takes place. During this period do not race, overload, or lug the engine.
Note the riding procedures described in the section “Running-In of New Motorcycle.” Following
those procedures will ensure that you have the most powerful & smoothly operating engine
after break-in.
Maintenance intervals recommended are based on operational experience under various climatic and
road conditions. However, these intervals may be extended or reduced following repeated checks of the
lubricant condition and general mechanical condition of the motorcycle.
Carefully study this Owner’s Manual before starting the motorcycle.
Specifications and design are subject to change without notice.
5
6
Chapter 1
SPECIFICATIONS
GENERAL
Retro
Maximum speed of motorcycle
Reference fuel consumption at 85% of
120 km/h 74 mph
14 km/L 33 mpg
Dry mass of motorcycle
Maximum load-carrying capacity
Noise level
680 lb.
400 lb.
below 80db
OVERALL DIMENSIONS
Length
Width
Height
Road Clearance
Seat height
Wheel base
2500 mm / 8 ft
1700 mm / 5 ft 6 in
1100 mm / 3 ft 6 in
125 mm / 5 in
840 mm / 33 in
1470 mm / 58 in
ENGINE
Type
Displacement
Cylinder bore
Piston stroke
Compression ratio
Rated horsepower
Rated rotational speed
Rated torque
Lubrication system
Lubricant
4 stroke, overhead valves, opposed twin-cylinder
745 cc
78 mm
78 mm
8.6 :1
26 KW / 35 BHp
5600 RPM
35 ft.-lbs @ 3750 RPM
Dual system of forced lubrication and splashing
SAE 20W/50
CARBURETOR
Carburetor type
Number of carburetors
Air cleaner
Fuel
PCV Valve
32 CVK Keihin
2
Paper Filter Element
91 octane premium unleaded gasoline
Internal Breather
7
ELECTRICAL
Ignition system
Ignition coil
Spark plugs
Ignition timing
Alternator
Battery
Headlight
135.3734.COM-2 (CDI)
135.3705-2
NGK BP7H
Automatic spark timer
35 amp / 12 Volt
Interstate #YTX20L-BS or equivalent
Sylvania Halogen 6024, 7" round sealed beam
TRANSMISSION
Clutch
Gearbox
Dry double-disk clutch
4 speed gearbox with reverse gear lever
GEAR RATIOS
I gear
II gear
III gear
IV gear
Reverse gear
3.6
2.28
1.5
1.19
4.2
Speedometer drive ratio
Final drive ratio
0.4
4.62
FLUID CAPACITIES
Fuel tank
Reserve
Engine
Transmission
Final drive
Shock Absorbers
5 Gal / 19L
.5 Gal / 2L
68 oz / 2L
34 oz / 1 L
3.5 oz / 105 ml
105 ml / 3.5 oz
RUNNING GEAR
FrameTubular welded
Rear wheel suspension
Front fork
Brakes
Tires
Swing arms with spring shock absorbers
Telescopic
Hydraulic Disk on front, Hydraulic Drum on rear
4” x 19”
Front 22 psi cold (1.5 Bar / 150 kPa) Front 22 psi cold
Rear 36 psi cold (2.5 Bar / 250 kPa) Rear 36 psi cold
8
CLEARANCES
Valves with engine cold
Between spark plug electrodes
Backlash between tooth faces of
bevel gears in final drive
mm
0.05 to 0.1
1.016
in
0.002 to 0.004
0.040
0.1 - 0.3
0.004
mm
5-8
5-8
¼ of full stroke of pedal,
25 - 30
in
0.2 - 0.3
0.2 - 0.3
FREE TRAVEL / ADJUSTMENTS
Hand brake control lever
Clutch control lever
Foot brake drive pedal
9
1.0 - 1.2
TORQUE SPECIFICATIONS
Metric
54 to 61 Nm
237 to 251 Nm
19 to 30 Nm top
38 to 49 Nm bottom
30 to 35 Nm
30 to 35 Nm
16 to 19 Nm
6.7 to 11 Nm
14 to 19 Nm
68 to 90 Nm
22 to 27 Nm
19 to 22 Nm
136 to 163 Nm
US Equivalent
40 ft/lb to 45 ft/lb
175 ft/lb to 185 ft/lb
14 ft/lb to 22 ft/lb
28 ft/lb to 36 ft/lb
22 ft/lb to 26 ft/lb
22 ft/lb to 26 ft/lb
12 ft/lb to 14 ft/lb
5 ft/lb to 8 ft/lb
10 ft/lb to 14 ft/lb
50 ft/lb to 66 ft/lb
16 ft/lb to 20 ft/lb
14 ft/lb to 16 ft/lb
100 ft/lb to 120 ft/lb
Location on Bike
cylinder heads
fly wheel tightening screws
shock absorber
shock absorber
bearing nut
final drive to swing arm bolts
oil pump bolt
engine sump
final drive case nuts
nut fastening the pinion bearing
reverse gear brake lever
alternator gear nut
steering stem nut
CONVERSIONS
To convert from mm to in, divide by 25.4 (there are 25.4 mm per inch).
To convert from liters to gallons, divide by 3.785 (there are 3.78 liters per gallon).
To convert from liters to quarts, multiply by 1.056 (there are 1.056 quarts per liter).
To convert from liters to pints, multiply by 2.112 (there are 2.112 pints per liter).
To convert from km to miles, multiply by .62 (there is .62 mile per km).
To convert from km/hr to mph, multiply by .62.
To convert from Newton-meter (Nm) to inch-pound, multiply by 8.86.
To convert from Newton-meter (Nm) to foot-pound, multiply by .7376.
To convert from cm3 (cc) to pints, divide by 473 (there are 473 cc per pint).
To convert Celcius to Fahrenheit: F° = C° x 1.8 + 32.
To convert Fahrenheit to Celcius, C° = (F° − 32) divide by 1.8.
10
Chapter 2
MOTORCYCLE CONTROLS & INSTRUMENTATION
19
20
2
3
4
18
1
16
17
14
13
7
15
5
6
8
10
12
9
11
Controls and Instrumentation
1 - Speedometer
2 - Turn indicator lamp
3 - Trip odometer reset knob
4 - Neutral and reverse gear engagement
indicator lamp
5 - Front brake control lever
6 - Throttle control twist grip
7 - Ignition cutoff switch
8 - Electric Start Button
9 - Rear brake pedal & sidecar wheel brake
10 - Reverse gear lever
11 - Kick start lever
12 - Gear shift (foot) pedal
13 - Turn signal switch
14 - Horn push-button
15 - “High-low” beam switch
16 - Clutch control lever
17 - Steering damper tightening bolt
18 - High-beam indicator lamp
19 - Ignition Switch
20 - Battery discharge warning lamp
21 - Parking brake
11
Clutch Control Lever
Clutch Control Lever
Front Brake Control Lever
Clutch control lever When the clutch lever is squeezed, the engine is disengaged from the
gearbox. When the lever is released, the engine and gearbox are connected.
WARNING: MAKE SURE FINGERS ARE NOT POSITIONED BETWEEN HAND CONTROL LEVERS AND HANDLEBAR
GRIPS OR OPERATION OF VEHICLE COULD BE IMPAIRED.
WARNING: BEFORE STARTING ENGINE, ALWAYS SHIFT TRANSMISSION TO NEUTRAL TO PREVENT ACCIDENTAL
MOVEMENT WHICH COULD CAUSE POSSIBLE DAMAGE TO MOTORCYCLE AND PERSONAL INJURY.
Caution: Always engage the clutch release lever when shifting. Serious internal damage may
result to the transmission if the clutch release lever is not engaged.
Front brake control lever When the lever is squeezed, the front wheel brake is actuated. The
front brake should be used together with rear brake. When the brake lever is squeezed, the stop
signal lights are switched on.
REAR BRAKE PEDAL IS USED TO ACTUATE THE REAR BRAKES.
12
Kick starter is designed to start the engine. On pressing the lever, the crankshaft of the engine is
rotated via the gearbox. The lever is returned to its initial position by a spring inside the gearbox.
Gear shift lever
Kick Starter
Reverse Gear Selector
Gear shift Lever. When the front pedal is pressed, shifting from higher to lower gear takes place.
When the rear pedal is pressed, shifting from lower to higher gear takes place. The neutral
position is fixed between the 1st and 2nd gears. It is important to shift smoothly with a constant force
and not to kick the gear shift pedal.
Reverse gear is engaged by pushing forward on the reverse gear selector. Reverse gear should
only br engaged from neutral or 1st gear, after the motorcycle has come to a complete stop. When
the reverse gear selector is pulled backward, the transmission will be in neutral.
IMPORTANT! The green pilot lamp will illuminate when the transmission is in neutral or
reverse gear. (see “Starting the Engine”).
WARNING: DO NOT LET YOUR FOOT REST ON THE EXHAUST HEADER PIPE. SERIOUS INJURY OR BURNS MAY
RESULT.
WARNING: DO NOT APPLY EITHER BRAKE STRONGLY ENOUGH TO LOCK THE WHEELS BECAUSE THIS MAY
13
CAUSE POSSIBLE LOSS OF CONTROL OF THE MOTORCYCLE.
ALWAYS USE BOTH BRAKES. NEVER STOP WITH
FRONT OR REAR BRAKE ONLY.
Ignition Switch has three fixed positions of the key.
The positions of the ignition are shown above.
Off
Run
Parking
All electrical systems are off.
Voltage is supplied to all electrical systems.
Voltage is supplied to running lights only.
Note: Leaving the key in the Run or Parking position will discharge the battery.
Always return the key to the Off position before removing it.
Ignition
Switch
Turn Signal
Alternator
Trip
Odometer
High
Beam
Neutral
Indicator
The indicator lamps are located on the instrument panel:
14
Engine Cutoff
Switch
Electric Start
Switch
Headlight
Hi / Low Beam
Switch
Turn Signal
Switch
Horn
Switch
15
CONTROL CABLE ADJUSTMENT
The control cables are adjusted by screw adjustments at the cable ends.
With the control levers released:
• for the clutch a play at the clutch lever end should be equal to 5 - 8 mm/0.2 - 0.3 in.
• for the carburetors - carburetor throttle cables synchronized
With the control levers (handles) fully depressed:
• for the clutch — complete disengagement of the engine from the transmission; noiseless shifting
of gears means good adjustment of the clutch cable.
• for the carburetors — lift of throttles to the maximum and equal height
CONTROL CABLE MAINTENANCE
The daily preventative maintenance involves checking the functioning, condition and fastening of
the tie rods, cables and braking action. Refer to the Service Coupons for lubrication schedule.
As per the service coupons, lubricate the throttle control twist grip, the lever pins and ends of
cables used in the clutch and the throttles.
SPEEDOMETER MAINTENANCE
After every 10,000 km, remove the speedometer from the motorcycle and add five or six drops of
oil into the speedometer where the cable inserts into the speedometer. This will lubricate the speedometer internally.
To lubricate the speedometer cable, remove the cable from the speedometer and pull straight. Use
speedometer lubricating oil or light machine oil.
16
Chapter 3
ENGINE OPERATION
PRE-TRIP PRELIMINARIES
Pre-Trip Check List
1.
2.
3.
4.
5.
Check all lights and the horn for proper operation.
Check the brake and clutch levers and/or pedals.
Make sure all wheels and the final drive assemblies are securely fastened .
Check the carburetor flanges and air filter ducts for integrity and proper alignment.
Check the tire tread depth - should be greater than 1/8 inch.
Gasoline level in the fully filled tank should be 10 - 15 mm / ½ - ¾ in. below the lower edge of the
tank filler. Do not overfill the tank.
See that the oil level in the engine crankcase is not higher than the top and not lower than the
bottom marks on the dipstick with the filler plug undone. (See chapter 4 Lubrication System)
CAUTION: When checking the engine oil level, be careful that dirt and debris do not
contaminate the oil.
STARTING THE ENGINE
WARNING: BEFORE STARTING THE ENGINE, MAKE SURE THAT THE GEAR SHIFT MECHANISM IS IN THE
NEUTRAL POSITION (BETWEEN 1ST AND 2ND GEARS) TO PREVENT ACCIDENTAL MOVEMENT WHICH COULD
CAUSE POSSIBLE DAMAGE TO MOTORCYCLE AND PERSONAL INJURY. ( FOR MORE THAN JUST STARTING, I.E.
IDLING, IT IS ADVISABLE TO USE NEUTRAL GEAR.)
When the ignition is switched on, the green & red lamps on the instrument panel should
illuminate. This will indicate that the battery is discharging while the engine is not running and that
the motorcycle is in neutral.
17
Prime Position
Fuel On
Position
Reserve Fuel
Position
1. When starting the engine after the motorcycle has been parked for an extended period of
time, or after the fuel tank and/or carburetors have been completely emptied of gasoline
(e.g. due running out of fuel, evaporation, or installation of replacement parts), set the valve
to the “PRI” (Prime) position. This would allow gasoline to fill the float chambers of the
carburetors and prepare the engine for starting.
2. Start the engine
3. After the engine starts, set the valve to the “ON” position and keep the valve in this position
for regular use of the motorcycle. (When set to “ON”, the valve is automatically activated
when the engine starts and stops, opening and shutting off the supply of fuel to the
carburetors)
4. After using up the main volume of fuel (engines starts stalling due to lack of fuel), set the
valve to the “RES” (Reserve) position and continue driving. After refueling, remember to set
the valve back to “ON” to avoid running out of fuel completely.
IMPORTANT: When parking the motorcycle for extended periods of time, the valve should
remain in the “ON” position.
WARNING: Never leave the motorcycle with the engine turned off and the valve set to “PRI”
as this may result in a serious damage to the engine and will void your warranty.
The carburetor enricheners provide extra fuel to the mixture. This extra fuel will allow a cold engine
to start and run until it has warmed up sufficiently to allow normal operation. Use caution when
using the enricheners, as they can easily cause the engine to flood, or foul the spark plugs. The
enricheners should only be left on as long as necessary to keep the engine running while cold and
should be turned off as soon as possible.
Depending on the engine and ambient temperature, use the carburetor enricheners and starting
procedure as follows:
18
Enrichener off
Enrichener on
Manual Starting (without electric starter)
1. Turn on the ignition and depress the kick lever about 1/4 of its travel (enough to firmly get
the ball of your foot on the lever) with either your left foot or right foot, depending on what
position is most comfortable with your right hand on the throttle. Take up the slack in the
throttle until you can feel some slight resistance from the return springs in the carburetors,
without any advance on the throttle, since this may flood the engine.
2. Give the kick lever a swift kick. When the engine starts, tickle the throttle (quickly increase and decrease it) to keep the engine running, but not too fast. If the engine doesn’t
start, repeat the kicking procedure. A properly adjusted warm engine should start within a
few kicks. If the engine doesn’t start, try the procedure described below in item
3. If it still doesn’t start or fire, it may be flooded.
Note: Do not completely open the throttle while kicking the engine over since it may flood the
engine and the spark plugs may become fouled with gasoline.
Electric Starting
1. Set carburetor enricheners as with kick starting. Unlike manual starting, however, the
gearbox does not have to be in neutral as the electric starter may be engaged with the clutch
lever pulled in, or with the gearbox in neutral. Make sure the Ignition Cutoff Switch is set to
“ Ignition On” and push the starter button to turn over the engine.
2. When the engine has been standing for several hours but the ambient temperature is
high (60°F/15°C degrees or above), try starting it without any enricheners. If it doesn’t fire,
then use the procedure described below.
19
3. When the engine is cool or cold and the ambient temperature is between40°F-60°F/5°C15°C, engage both enricheners to start. As soon as the engine starts, immediately retract
the enricheners. Run the engine at moderate speed for 30-60 seconds. If it starts to die,
blip the twist grip throttle (rapidly twist part way towards full throttle and then back off) to keep
the engine running. After 1 to 3 minutes, depending on ambient temperature, the engine
should run smoothly without “blipping” the throttle.
4. If the engine is cold and ambient temperature is below 40°F, first, give the engine 5-10
(depending on how cold it is) priming kicks with the ignition off. This will get some oil
circulated to key internal parts. Engage the enricheners on both carburetors. The engine
should
then fire, depending on how cold it is. For example, when the ambient temperature is 0°F, it
typically takes about 5-10 rotations to start the engine. As soon as the engine starts, retract
both enricheners (after a few seconds).
Note: It is very important to back off on the enricheners as soon as the engine will sustain
itself without stalling. Since the Ural is a carbureted air cooled engine, the plugs will foul quickly
(as soon as one minute) if the engine mixture is too rich. If one plug fouls and the other doesn’t,
the engine will run unevenly and may cause internal damage.
When the engine is hot, do not choke or enrichen the carburetors. To do so risks flooding the
engine.
To start an engine that is flooded, first open the throttle fully, hold it there and give the engine up
to 10 swift kicks. If it still doesn’t fire, take the spark plugs out to see if they are wet with
gasoline. If they are wet, dry them. Clear excess gasoline from the cylinders by kicking the
engine over 10 times with the plugs out and the throttle closed. Then replace the plugs and
repeat the starting procedure described at the beginning of this section (1).
WARNING: SUSTAINED OPERATION ON ONLY ONE CYLINDER FOR EVEN JUST A FEW MINUTES COULD
OVERHEAT THE CYLINDER AND CAUSE IRREVERSIBLE DAMAGE TO EITHER THE VALVES OR PISTON. THUS IT IS
CRITICAL TO IMMEDIATELY SHUT THE ENGINE DOWN IF IT APPEARS TO BE RUNNING ON ONLY ONE CYLINDER.
Additional Warnings: Once the engine starts, do not allow it to run at a high speed as this could
cause abnormal wear of the parts and may lead to seizure of the piston pin and pistons in the
cylinders since cold oil flows through the oil ducts with difficulty and fails to ensure sufficient
lubrication. A correctly adjusted warm engine should run steadily at low speed with the throttle
control
twist grip fully closed.
Do not let the motorcycle sit at idle for more than three minutes, as overheating could result.
20
OPERATING PRECAUTIONS
WARNING: MAKE SURE THAT SIDECAR WINDSHIELD IS IN THE FULL BACK POSITION SO IT DOESN’T
INTERFERE WITH THE RIGHT HANDLEBAR.
To move the motorcycle from rest, shift to 1st gear only. Avoid releasing the clutch suddenly,
because the engine is liable to stall or the motorcycle will start with a jerk. Do not drive the
motorcycle at speeds below the recommended speeds with the 2nd, 3rd or 4th gears engaged. It is
not advisable to use the 1st and 2nd gears for a long time, unless so required by road conditions.
RUNNING IN THE NEW MOTORCYCLE
The running-in period for the motorcycle is the first 1,500 km.
There are no special procedures that must be followed, but during the running-in period, a new
motorcycle requires the most careful attention. In the course of this period, do not overload the
machine. Avoid traveling on freeways and climbing steep hills. Do not race the engine or overheat
it at any time. Vary the throttle setting frequently, so as to avoid constant RPMs. Allow the new
engine frequent rest periods for cooling down.
WARNING: SHIFTING TO LOWER GEARS WHEN SPEED IS TOO HIGH MAY SEVERELY DAMAGE THE
TRANSMISSION OR CAUSE THE REAR WHEEL TO LOSE TRACTION.
CAUTION: Do not run the engine at extremely high rpms with clutch disengaged or
transmission in neutral. Do not idle the engine unnecessarily for more than a few minutes
with the motorcycle standing still.
When operating the Ural motorcycle on the highway, please try not to run continuously at speeds
above 65mph. If it is necessary to drive at speeds of 65mph and above let the engine cool by
running at a reduced speed for 10 - 15 minutes every 30 minutes if possible, this will provide longer
engine life.
WARNING: WHEN RIDING ON WET ROADS
OR UNDER RAINY CONDITIONS, BRAKING EFFICIENCY IS GREATLY
REDUCED AND CAUTION SHOULD BE USED WHEN APPLYING THE BRAKES, ACCELERATING OR TURNING.
THIS IS
ESPECIALLY TRUE IMMEDIATELY AFTER THE RAIN BEGINS AND THE OIL FROM THE ROAD SURFACE COMBINES
WITH THE WATER.
When descending a long, steep grade, downshift and use engine compression together with
intermittent application of both brakes to slow the motorcycle. Avoid continuous use of brakes to
reduce overheating of the brakes and reduced efficiency.
While using the motorcycle in summer, pay special attention to the condition of the tires. Keep
them inflated up to pressures specified in this manual.
21
22
Chapter 4
ENGINE DESIGN
The motorcycle is equipped with a two-cylinder four-stroke air-cooled engine. The opposed arrangement of cylinders in the horizontal plane is the outstanding feature of the motorcycle design
which ensures proper cooling and balancing of the crank gear. The engine valves are located in
the cylinder heads.
In summer, carefully observe the heating condition of the engine, power transmission units and the
running gear mechanisms. Under normal heating conditions of the engine, the temperature of the
cylinder heads should not be over 356°F-428°F/180°C-220°C.
During everyday preventive maintenance, clean the engine of mud and dust, paying special attention to the cooling fins as their fouling will impair the efficiency of the engine cooling. Check engine crankcase, cylinders and cylinder heads for oil and fuel leaks. Check carburetor to cylinder
head adapter for any cracks or leaks. Visually inspect the alternator for any oil leaks.
23
LUBRICATION SYSTEM
The motorcycle engine features a dual lubrication system, some parts are force-lubricated by
pressure built up by the oil pump, while others by splashing . A full-flow paper oil filter is provided
in the lubrication system to prolong the engine life.
Maintenance of lubrication system. During the daily inspection, check the oil level in the engine
crankcase and top off the oil if necessary. Warm up the engine before changing the oil. Drain
used oil from the engine and the oil filter cavity after having unscrewed the drain plug and filter
plug. Change oil filter at the intervals shown in the service coupons. Set the rubber sealing bushing into the filter and fit the filter with the bushing onto the adapter of plug, then screw the latter into
the front cover. Now screw in the plug. Fill the engine with 68 oz. oil, or until the top mark of the
dipstick is reached.
Let the engine run for 3 - 5 min. Check the oil level again adding oil up to the top groove of the
dipstick if needed. During motorcycle service, keep oil level in the engine crankcase close to the
top groove of the oil dipstick. Don’t ride the motorcycle if the oil level is below the lower mark of the
dipstick until sufficient oil is added to raise the oil level to the top mark.
Correct position to measure the oil level
Make sure that the dipstick is screwed down securely after checking the oil level.
24
FUEL SYSTEM
The fuel system includes the gasoline tank, the three position fuel valve with filter and two
carburetors.
Petcock Location
Petcock
Fuel valve (petcock). The top threaded portion of the valve is screwed into the gasoline tank. The
petcock is of an automatic shutoff design. Vacuum from the engine opens the valve when the
engine is running. When the engine is stopped and looses vacuum, the petcock automatically
shuts off.
WARNING: FILL FUEL TANK SLOWLY TO PREVENT FUEL SPILLAGE. DO NOT OVERFILL ABOVE THE BOTTOM OF
FILLER NECK INSERT. LEAVE AIR SPACE TO ALLOW FOR FUEL EXPANSION. FUEL EXPANSION CAN CAUSE
OVERFLOW THROUGH THE FILLER CAP VENT ONTO SURROUNDING AREAS. AFTER REFUELING, MAKE SURE
FILLER CAP IS SECURELY TIGHTENED.
Fuel system maintenance. Before a trip, check the tightness of gasoline piping joints, & proper
functioning of throttle cables.
25
IGNITION SYSTEM
The ignition system incorporates the power supplies, ignition coil, Hall Effect pickup, electronic
module, two spark plugs, a set of low and high voltage wires and the ignition switch.
The ignition system will provide the spark to the spark plugs from 200 to 6000 RPM. With the
engine at rest, the ignition system will draw 100 mA. With the engine running, the ignition system
will draw 1.5 Amps. The operating voltage for the ignition system ranges between 7 to 16 Volts.
The electronic ignition system will automatically provide the required changes in timing to an accuracy of within + 1°.
Ignition coil The ignition coil has two high voltage terminals, each supplying one of the cylinder
spark plugs and operating in conjunction with the Hall Effect pickup.
Periodically, check all wires in the ignition system to be sure they aren’t crimped or have loose
connections. Loose connections will cause erratic performance and poor fuel economy.
Spark plugs. In certain situations, spark plugs can quickly foul with carbon or soot. The plugs can
be cleaned but it is easier to put in a new set of plugs when on the road. We recommend that you
purchase an extra set of these plugs from your Authorized Ural Dealer and carry them in the motorcycle at all times.
WARNING: DO NOT OVERTIGHTEN THE SPARK PLUG WHEN MOUNTING IT ON THE ENGINE, SINCE THIS COULD
DAMAGE THE CYLINDER HEAD.
Functioning of ignition system. Both plugs fire simultaneously on the left and right-hand cylinders, one spark being formed when the compression stroke terminates in one of the cylinders and
the other during the exhaust stroke.
IGNITION TIMING
To set the ignition timing, proceed as follows:
-Match the first mark on the flywheel with the center marks on the engine flywheel window.
-Loosen the fastening screws of the microprocessor unit and turn it counterclockwise until it stops.
-Apply power to the ignition system by switching the ignition on.
-Slowly turn the ignition unit clockwise, (the LED should be on)
-Stop turning the microprocessor unit when the LED turns off.
-Tighten the fastening screws of the microprocessor unit and switch the ignition off.
26
Ignition Module & Coil
27
28
Chapter 5
CARBURETORS
32mm CVK Keihin Seike carburetors are used on of the Ural motorcycle. They are preset with
fixed mixture jetting and adjust automatically for altitude variations. This is due to the vacuum activation mechanism of these constant velocity type carburetors. Be sure to check the condition of all
carburetor adapters and air pipes every time before riding. If the carburetor flanges are in need of
replacement, use only genuine Ural replacement or Ural recommended parts.
Flange
Carburetor
Branch Pipe
WARNING: TO AVOID SEVERE ENGINE DAMAGE, DO NOT MODIFY CARBURETOR SYNCHRONIZATION, JETS, OR
THROTTLE LINKAGE. THIS AIR COOLED ENGINE MUST ALWAYS RUN ON BOTH CYLINDERS AS EVENLY AS POSSIBLE. WHENEVER ONE CYLINDER IS NOT FIRING, STOP THE ENGINE AND DETERMINE THE CAUSE AND CORRECT
IT BEFORE PROCEEDING.
WARNING: Never use a metal adapter between the carburetor and cylinder head. This will
automatically void the warranty and may cause significant damage.
29
CARBURETOR MAINTENANCE
The carburetors will require the sediment in the float bowls be drained periodically. This will ensure
that any contaminants that have accumulated in the float bowls do not enter the main or idle jets of
the carburetors. The fuel can be drained by opening the drains provided on the bottom of the float
bowls.
The fuel filters should also be changed every 10,000 km or when they appear to be dirty or not
flowing fuel correctly. Changing the filters will ensure that clean fuel is provided to the carburetors
and that there is no fuel starvation.
The carburetor to cylinder head adapters should be checked for leaks and cracks every trip. Failure of the adapters will cause the carburetor fuel mixture to become lean and cause internal damage to the engine.
30
Chapter 6
POWER TRANSMISSION
The power transmission of the motorcycle is comprised of the clutch, gearbox, drive shaft and the
final drive.
CLUTCH
The clutch transmits torque from the engine to the gearbox. Disengage the engine from the gearbox during shifting of the gears and during braking to a stop. The clutch provides for smooth
starting of the motorcycle from rest, protects the power transmission parts against damage when
the engine speed or drive wheel speed is suddenly changed. The clutch is of dry double-disk
design. The clutch release mechanism is controlled by the lever on the left grip of the handle bar.
With the clutch lever released, the engine is engaged to the gearbox. When the clutch lever is
squeezed, the engine is disengaged from the gearbox. Use the clutch lever for starting from
rest and for gear shifting. Under conditions of heavy traffic, when gears frequently have to be
shifted, do not slip the clutch too much, as this will accelerate wear of the disks.
GEARBOX
Shifting the gears is best accomplished by pushing down on the front toe plate for first gear and to
downshift from higher gears. To shift up into second, third and fourth gear, use the front toe plate
and push upwards quickly and firmly. Since the Ural transmission is a non-synchronized design, it
is very important that the clutch be used when shifting. Not using the clutch when shifting can
cause damage and void the warranty.
CAUTION: Severe damage due to insufficient lubrication of gears, shafts and bearings can
result if the oil level is allowed to get lower than the specified level.
FINAL DRIVE
Maintenance of propeller shaft splines and final drive.
Remove the final drive from the swing arm and pull the final drive towards the rear of the bike.
When the drive shaft is free, coat the drive shaft splines with grease. At the same time, use a
grease gun to force grease into the drive shaft universal joint.
Typical final drive maintenance includes tightening the nuts which fasten the final drive to the
swinging fork arm. Failure to tighten the nuts may result in loose joints and the destruction of the
final drive cover. Change the final drive oil as determined by the service coupons. Undo the filler
and drain plugs and drain the used oil. Reinsert the drain plug and fill the casing with fresh 20w /
50 Castrol oil and flush the final drive by turning the rear wheel several times. Drain the 20w / 50
31
Castrol oil and then refill the final drive with the specified lubricant. Reinsert the upper fill plug and
wipe off any excess or spilled oil from the final drive.
Filler Plug
Universal Joint
Splines
Drain Plug
Final Drive Assy
Rear Universal Joint
32
Chapter 7
RUNNING GEAR
SPRING LOADED HYDRAULIC SHOCK ABSORBER
The suspension features cam-type adjusters used for varying the pretension of the supporting
springs to suit the load and the road condition. The degree of tension of the springs is adjustable
allowing two positions. The first (lower) position corresponds to the load due to the motorcycle’s
own weight and the driver’s. the second (upper) position of moving cam corresponds to the maximum load.
Care of shock absorbers. Fill the shock absorber with 105 cm³ of hydraulic fluid. Each time
during maintenance, check the bolts fixing the top and bottom ends of the shock absorbers for
tightness.
33
FRONT FORK
The front fork used on the wolf model uses a telescopic design. To maintain the fork, change the
fluid when it is called for in the service coupons and keep the forks free from dust and dirt. Consult
your dealer for details on changing the front fork fluid.
STEERING HEAD BEARINGS
The steering head bearings must be adjusted periodically to avoid excessive play which might
cause steering instability. When properly adjusted, the front fork should turn with just a hint of
bearing drag, but not free play or obvious resistance to turning. The steering head bearings are of
a roller bearing type and are designed for the lifetime of the motorcycle.
WARNING: IMPROPER ADJUSTMENT OF THE STEERING HEAD (E.G. TOO TIGHT) WILL MAKE THE MOTORCYCLE
VERY DIFFICULT TO STEER. THIS ADJUSTMENT IS CRITICAL FOR PROPER HANDLING OF ALL MODELS.
Steering Head Bearing Location
34
Chapter 8
WHEELS AND TIRES
The Ural motorcycle is equipped with wheels that are easy to remove.
Removing wheels. To remove the front wheel, set the motorcycle onto the center stand, lift it by
the front wheel and put a rest under the front portion of the motorcycle frame. Slacken the nut of
the union bolt at the end-piece base of the fork left-hand leg. Screw out the axle turning it clockwise (left-hand thread) and remove the wheel together with the front brake disc.
To reinstall the front wheel on the motorcycle follow the reverse order of the above operations
seeing to it that the brake disc evenly engages with the brake caliper.
To remove the rear wheel of the motorcycle, lift the motorcycle onto the center stand. Undo the rear
wheel axle nut and take it off together with the washer, slacken off the nut on the union bolt of the
left-hand leg of the swinging arm, pull out the rear wheel axle with the help of a wrench bar and
remove the wheel.
To reinstall the wheel on the motorcycle follow the reverse order of operations. Prior to reassembling, wipe the axle and grease it. Fitting the rear axle, turn it as you push it in to avoid jamming.
Care should be taken to keep tires properly inflated. Check before riding when tires are cold. Do
not overinflate tires.
Warning: Never interchange the front for the rear wheels.
WARNING: IMPROPER TIRE INFLATION WILL CAUSE ABNORMAL TREAD WEAR AND COULD RESULT IN UNSTABLE HANDLING. UNDER-INFLATION COULD RESULT IN THE TIRE SLIPPING ON THE RIM.
Front
tire pressure
Rear
tire pressure
1.5 Bar
2.5 Bar
35
Front
tire pressure
Rear
tire pressure
or 150 kPa
or 250 kPa
WARNING: RIDING WITH EXCESSIVELY WORN, UNBALANCED OR IMPROPERLY INFLATED TIRES IS HAZARDOUS
AND WILL ADVERSELY AFFECT TRACTION, STEERING AND HANDLING. SAME AS ORIGINAL EQUIPMENT TIRES
MUST BE USED. OTHER TIRES MAY NOT FIT CORRECTLY AND MAY BE HAZARDOUS TO USE.
BECAUSE TIRES, TUBES AND WHEELS ARE CRITICAL SAFETY ITEMS AND SERVICING OF THESE ITEMS REQUIRES
SPECIAL TOOLS AND SKILLS, WE RECOMMEND YOU SEE YOUR URAL DEALER FOR THESE SERVICES.
TIRE DATA
WARNING: FOR YOUR OWN PERSONAL SAFETY, TIRES AND TUBES MUST BE CORRECTLY MATCHED TO WHEEL
RIMS. SEE YOUR AUTHORIZED URAL DEALER FOR FURTHER INFORMATION. MISMATCHING TIRES, TUBES AND
RIMS MAY RESULT IN DAMAGE TO THE TIRE BEAD DURING MOUNTING OR MAY ALLOW THE TIRE TO SLIP ON THE
RIM, POSSIBLE CAUSING TIRE FAILURE.
IN ADDITION, USING TIRES OTHER THAN THOSE SPECIFIED MAY ADVERSELY AFFECT MOTORCYCLE STABILITY. PROTECTIVE RUBBER RIM STRIPS MUST BE USED. TIRE SIZES ARE
MOLDED ON THE TIRE SIDEWALL. TUBE SIZES ARE PRINTED ON THE TUBE.
URAL tires that have been tested by the manufacturer to ensure compliance with DOT requirements
are available from your Authorized IMWA Dealer.
WARNING: MAXIMUM INFLATION PRESSURE MUST NOT EXCEED SPECIFICATION ON TIRE SIDEWALL.
WARNING: WHEN TIRES ARE WORN TO A TIRE CENTER TREAD DEPTHS OF 3/32 IN, THEY SHOULD BE REPLACED.
36
WHEEL AND TIRE MAINTENANCE
During the pre-trip inspection, check air pressure in the tires.
Check axle and spokes for safe fastening, be sure to tighten the spokes or fasteners and eliminate
play as soon as they get loose or demonstrate excessive play.
While lubricating, consult the Lubrication Chart.
WARNING: WHEEL TRUING INVOLVING MORE THAN 2 TURNS OF ANY SPOKE NIPPLE SHOULD BE ACCOMPLISHED WITH THE TIRE DISMANTLED SO THAT SPOKE ENDS CAN BE CHECKED TO ENSURE NO SPOKES PROTRUDE INTO THE INNER TUBE.
Wheel Construction
Two adjustable tapered roller bearings are pressed into the wheel hub, which are prelubricated with
LITOL-24 type grease. Depending on motorcycle version the wheels with aluminum cast brake drum
or disc type may be used. The adjustment of bearings is the same for both styles of wheel.
Adjustment of Wheel Bearings.
The life of wheel bearings is extended by proper adjustment. Check
the condition of bearings and adjust them every 5000 km. To
adjust the bearings proceed as follows:
- Remove the wheel from the motorcycle;
- Fit the rear wheel axle (without protective cap), tighten it by
nut with the aid of a bushing, 100 mm long, with 21 mm ID
and 25…30 mm OD, or a set of bushing of given size.
- Determine if there is a play by turning the axle (but not the
wheel on the axle) and rocking it, slacken off the lock nut.
- Screw the seal nut up to the limit, then release it by 1/6..
1/8 of the turn so that the axle-bushing system rotates without
play, easily and without jamming. The overtightening of
bearings is strictly prohibited.
- Tighten the lock nut without effecting the bearing adjustment.
- Pull the axle out.
- Put the wheel onto the motorcycle.
37
38
Chapter 9
BRAKES
The motorcycle is equipped with a hydraulic disc brake in front and hydraulic drum on the rear.
The hydraulic disc brake consists of a caliper, brake pads and a wheel disc.
Front Brake
Reservoir
The front brake is a hydraulic disc brake.
The front brake hydraulic reservoir is located on the right handlebar.
39
Differential
Dipstick
Brake Line
The rear wheel brake is mounted in the rear hub, and is actuated via a hydraulic master cylinder
linked to the brake pedal.
Rear Brake Hydraulic Reservoir
40
Brakes should be “burnished in” during the initial running in period. Follow burnishing procedures
carefully. Make approximately 100 stops using 75% of full braking power. This can be done over
several periods and need not be done in one session. Choose an area with clean, dry pavement
and no obstructions. Travel in a straight line and apply both the hand (front) brake as well as the
foot (rear and sidecar) brakes. This procedure will ensure maximum braking performance during
the running-in period and is essential before raising your top speed, after your Ural has been
carefully run in (after 1,500 km).
WARNING: BECAUSE BRAKE PERFORMANCE IS A CRITICAL SAFETY ITEM, WE RECOMMEND THAT YOU SEE
YOUR IMWA DEALER FOR THESE SERVICES.
BRAKES MUST BE INSPECTED FOR WEAR AS PER THE SERVICE COUPONS IF THE BRAKE SHOE FRICTION
MATERIAL IS 1/16 IN. THICK OR LESS (THE THICKNESS OF A NICKEL) THE SHOES MUST BE REPLACED IMMEDIATELY. FAILURE TO REPLACE PADS WHEN NECESSARY COULD RESULT IN BRAKE MALFUNCTION AND PERSONAL
INJURY. IF YOU RIDE UNDER ADVERSE CONDITIONS, STEEP HILLS, HEAVY TRAFFIC, ETC., MORE FREQUENT
INSPECTION, 1,000 KM OR LESS, WILL BE NECESSARY. THE HYDRAULIC BRAKE FLUID SHOULD BE INSPECTED BY
REMOVING THE TOPS OF THE HYDRAULIC RESERVOIRS & CHECKING FOR ADEQUATE FLUID LEVELS.
41
42
Chapter 10
ELECTRICAL EQUIPMENT
The electrical equipment of the motorcycle includes power supplies, auxiliary instruments and
electric wiring.
Electric power supplies are a battery and an alternator with a built-in rectifier.
A single wire system is used for wiring the electric circuits, i.e. a single wire carries power to the
electrical devices and the frame and engine serve as the second wire (called the “ground”). The
negative pole of the battery is connected to the motorcycle frame through the battery master
switch. The alternator makes electrical contact to the motorcycle engine and frame through its
mounting bolts.
Battery supplies electric power to all the systems of the motorcycle when the engine (and alternator) have stopped.
An alternator with a built-in rectifier is driven by the engine camshaft driven gear. The alternator is secured with two studs on the engine crankcase. At the drive side, the alternator cover is so
designed that by turning the alternator on the studs, the backlash adjustment of the gear mesh gap
can be made.
Electric horn. The motorcycle is equipped with a horn which sounds when the ignition is on and
the horn button is pressed. The horn can be tuned for loudest performance with an adjusting
screw located at the rear portion of the horn body.
Headlight. A 7" diameter DOT approved sealed beam headlight is used on the Ural. Adjust it so
that the high-beam is horizontal when the motorcycle is in its normal loaded condition.
ELECTRICAL CIRCUITS
Lead acid batteries such as those found in motorcycles are designed for a charging voltage of
14.25 volts. Batteries which are subjected to greater than 14.25 volts for extended periods of time
can suffer permanent damage due to the electrolyte boiling dry. Charging voltage of less than
14.25 volts will result in an inadequate charge delivered to the battery.
Automotive batteries operate at 12 volts. This is not enough voltage to harm people in any way.
However, the battery stores a huge amount of electricity in the form of electrons. If the electrons
43
are allowed to flow from the battery without restriction, then the wires carrying the electricity will
become hot enough to melt. The melting wires are extremely dangerous and can easily burn you.
Most problems in automotive electrical circuits are caused by poor connections. Make sure that all
connection points are clean and tight.
If the flow of electricity through a wire is interrupted due to a break in the wire or a poor connection, then the circuit is said to be “an open circuit”
The flow of electricity through a circuit always takes the path of least resistance. If there is an
accidental path of extremely low resistance created in a circuit, the circuit is said to have a “short
circuit” A short circuit will usually result in the melting of the fuse protecting that circuit.
ELECTRICAL EQUIPMENT MAINTENANCE
During the daily preventive inspection, check the functioning and the condition of the electrical
equipment. Inspect and or replace the spark plugs and ignition leads as required in the Service
Coupons. The gap is readjusted by bending the end of the side electrode.
Care of alternator. In the course of daily inspection, check the fastening of wires to the alternator
terminals, fastening of the alternator on the engine crankcase, backlash of the gears (by listening).
In case of too little backlash of the drive gear, excessive wear and overheating of the alternator
bearings take place.
Check for proper tightening of:
· nuts of the binding post bolts
· the alternator clamping screws
· the alternator fastening nuts
as often as outlined in the Service Coupons.
WARNING: Do not add any electrical accessories to your Ural motorcycle, as this may void
portions of the warranty
44
Fuse box (Inside of headlight bucket)
The headlight relays are located under the fuel tank
45
Wiring Diagram
46
Chapter 11
MAINTENANCE OF MOTORCYCLE
Maintenance should be performed after the specified total kilometers run irrespective of the technical condition of the motorcycle.
Different service duties and technical condition of the motorcycle may necessitate a change in the
intervals.
The Lubrication Chart indicating lubrication points of the motorcycle is given in Fig. 35. A summary of lubrication maintenance is given in the lubrication chart.
Cosmetic Maintenance
The enjoyment and resale value of your vehicle is greatly enhanced by consideration to the “look”
and cosmetic perfection of your vehicle. Due to the numerous metal surfaces on a motorcycle,
special care must be taken to prevent rust from occurring and/or to removed any rust or oxidation.
LIST OF RECOMMENDED LUBRICANTS
Lubrication Area
Detergent Oil Quantity
Engine
Transmission
Single Wheel Final Drive
20w/50 Castrol 68 oz. ( 2.0 L ) 1
20w/50 Castrol 34 oz. ( 1.0 L ) 2
80/90 wt.Gearlube 3.5 oz. ( 105 ml )
1 68 oz. is an approximate measure. The exact oil quantity will be whatever is required to
bring the oil level at the top mark of the dipstick.
2 34 oz. is an approximate measure. The exact oil quantity will be whatever is required to
bring the oil level up to the bottom thread of the transmission oil filler hole.
Note: Some leakage, seepage or dripping of oil and/or other lubricants is normal. It is not indicative of any malfunctioning and therefore is not covered as a warranty item unless motorcycle
operation or safety are materially affected.
47
LUBRICATION CHART
PART TO BE LUBRICATED
Engine crankcase
Transmission
Air cleaner
Telescopic forks
Final Drive
Brake pedal shaft
Drive shaft universal joint
Lever pins & end pieces of clutch & hand brake cables
Wheel bearing
Front forks
Carburetor throttle control twist grip
Speedometer flexible drive cable & speedometer axle
Steering column bearings
LUBRICANT
20W/50 Detergent Oil
20W/50 Detergent Oil
JR Filter Oil
5wt-10wt Fork Oil
80/90 Gear oil
Grease
Grease
Grease
Grease
Spindle oil & WD-40
Grease
Spindle oil
Grease
REQUIRED LUBRICATION
The Ural has been certified for EPA with SAE 20W/50 petroleum based detergent oil. This oil is
used in both the engine and transmission.
CARE OF MOTORCYCLE PAINT
When washing the motorcycle, use a weak stream of cold or slightly heated water. Never use a
pressure washer! Do not remove dust and mud by rubbing the surface with a dry cloth as sand
particles will degrade the surface and the paint will rapidly lose its brilliance. While washing, do not
use soda solution, kerosene, citric acids or mineral oils. If the surface is stained with mineral oil,
degrease by wiping with a rag. If after removal of mud and dust with a jet of water, some dirt is left
on the surface, remove it with the help of a sponge, a soft hair brush or a flannel and water, but not
allowing separate water drops to dry out on the surface. Finally, polish the painted surfaces with a
dry soft flannel.
To repair painted areas, each motorcycle is furnished with a bottle of matching touch up paint.
For patching proceed as follows:
· clean the surface with turpentine
· rub the damaged spot with a waterproof abrasive cloth and water rub thoroughly
· paint using a soft brush or a spray gun.
48
After patching, let the surface dry in air for 15 minutes. Then proceed with drying at 212°F-248°F/
100°C-120°C with the aid of heat reflector or an electric lamp until the coat is perfectly dry.
Bear in mind that enamels are flammable. Color match may not be perfect due to humidity, fading,
temperature and other variables.
The painted surfaces of the motorcycle feature natural gloss. In case some dull spots appear,
remedy them by polishing as follows. Take a solution of wax polishing compound and having
washed the dull spots thoroughly, smear a thin film of the compound with a soft wad (cotton, cotton
gauze or flannel) over the surface. Rub the polishing compound making circular motions with the
wad. In 3 - 5 min. of drying, wipe the surface with a clean dry piece of cloth or flannel until luster
appears.
PRESERVATION AND STORAGE
If the motorcycle is put in storage for the season, arrange it on supports and proceed with the
preservation treatment. Check that the wheel tire pressure is within specifications. Store the motorcycle away from acids, alkalis, mineral fertilizers and other harmful substances.
Prior to placing it in storage, clean the bike thoroughly, drain the carburetors, or start the engine
and let it run with the gasoline cock closed to remove gasoline in the float chambers of carburetors.
Then spray storage oil (WD40) into each cylinder through the spark plug holes. Turn the crankshaft by depressing the kick lever pedal to distribute lubricant over the interior of the cylinders.
Lubricate the surfaces of chrome and zinc plated parts with a rust inhibitor. Smear all the points
provided with grease cups with commercial grease. Seal the outlet holes of the mufflers.
Before starting a trip on the motorcycle that was under preservation, proceed with the jobs listed in
the section “Pre-Trip Preliminaries”.
Winter Considerations
Motorists in many areas of the US experience the use of salt and other chemicals that are applied
to road surfaces in the winter.
Salt or other caustic chemicals should always be removed from your bike’s surfaces with fresh
water as soon as possible.
Undercoating of fenders is recommended for those areas with salt and/or fine gravel or sand. See
your dealer for details.
49
BATTERY
Storage batteries on the motorcycle should function at ambient air temperature from -40°C to plus
60°C/ 40°F to 140°F.
As the battery is in service:
• regularly check the voltage for 13.8 - 14.2 V
• do not allow the battery to discharge.
• use only distilled water to maintain the normal level of electrolyte.
• coat bolts, nuts, washers and tips with petroleum jelly or battery grease. Use two wrenches for
clamping or undoing the nuts to avoid breaking battery parts.
Warning: Do not short the terminals together to check for sparking.
Before storage, fully charge the batteries, wash the battery surface with water and wipe dry, clean
the bolts and nuts of dirt.
WARNING: BATTERIES CONTAIN SULFURIC ACID WHICH CAN CAUSE SEVERE BURNS. AVOID CONTACT WITH
SKIN, EYES OR CLOTHING. ANTIDOTE: EXTERNAL — FLUSH WITH WATER. INTERNAL — DRINK LARGE
QUANTITIES OF WATER FOLLOWED BY MILK OF MAGNESIA, VEGETABLE OIL, OR BEATEN EGGS. CALL DOCTOR
IMMEDIATELY.
Caution: When charging the battery, disconnect the positive terminal (+) from the battery to
prevent damage to the electrical components Never jump-start the motorcycle!
WARNING: BATTERIES PRODUCE EXPLOSIVE HYDROGEN GAS AT ALL TIMES — ESPECIALLY WHEN BEING
CHARGED. KEEP CIGARETTES, OPEN FLAME, AND SPARKS AWAY FROM BATTERY AT ALL TIMES. VENTILATE
AREA WHEN CHARGING BATTERY. ALWAYS PROTECT HANDS AND PROTECT EYES WITH SHIELD OR GOGGLES
WHEN WORKING NEAR A BATTERY OR ACID. KEEP BATTERIES AND ACID OUT OF THE REACH OF
CHILDREN!
CAUTION: If battery is filled to a higher level than specified, some of the solution will be
forced out through the vent tube when battery is charging. This will not only weaken the
solution, but also may damage parts near the battery. To prevent battery case damage
caused by pressure buildup, be sure vent tube is properly routed and not kinked or obstructed.
50
LIST OF INDIVIDUAL TOOL SET,
SPARE PARTS, ACCESSORIES & DOCUMENTS
DESCRIPTION
Tools
Accessories
1. Wrench 7 x 8
2. Wrench 10 x 12
3. Wrench 13 x 14
4. Wrench 14 x 17
5. Wrench 19 x 22
6. Socket wrench 10 x 12
7. Socket wrench 10 x 13
8. Socket wrench 19 x 21
9. Wrench 27 mm
10. Double head wrench
11. Spanner wrench
12. Spanner wrench assembly
13. Screwdriver 150 mm
14. Screwdriver 100 mm
15. Punch
16. Allen wrench
17. 22mm Round wrench
(Patrol only)
QTY
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
DESCRIPTION
1. Air Pump
2. Air Pressure Gauge
3. Ignition keys
QTY
1
1
2
Set of Spares
1. Oil filter element
2. Fuses
3. Touch up paint
1
2
1
Documents
1. Owner’s Manual
1
51
52
Chapter 12
SAFE OPERATING RULES
Before operating your Ural it is your responsibility to read and follow operating and maintenance
instructions in this manual and follow these basic rules for your personal safety.
• Know and respect the Rules of the Road in your state.
• Use only Ural approved parts and accessories.
• Gasoline is extremely flammable and is explosive under certain conditions.
• Refuel in a well ventilated area with the engine stopped. Do not smoke or allow open
flames or sparks when refueling or servicing the fuel system. Always close the fuel
supply valve when the engine is not running to prevent flooding of the carburetors. Do
not overfill fuel tank. Fill tank slowly to prevent fuel spillage. Leave air space to allow for
fuel expansion. Do not fill more than about an inch below the lower edge of the tank filler.
• Motorcycle exhaust contains poisonous carbon monoxide gas. Do not inhale exhaust
gases and never run the engine in a closed garage or confined area.
• Before starting engine, check for proper operation of brake, clutch, shifter,
throttle controls, correct fuel and oil supply.
• A new motorcycle must be operated according to a special break-in procedure (see
Running-In The New Motorcycle).
• Operate the motorcycle only at moderate speed and out of traffic until you
have become thoroughly familiar with its operation and handling
characteristics under all conditions. If you are an inexperienced rider we
recommend that you obtain information and training in correct motorcycle
riding technique.
• Do not exceed the legal speed limit or drive too fast for existing conditions.
Always reduce speed when poor driving conditions exist. High speed
increases the influence of any other condition affecting stability and the
possibility of loss of control.
• Pay strict attention to road surfaces and wind conditions. Any two or threewheeled vehicle may be subject to upsetting forces. Wind blasts from passing trucks,
holes in the pavement, rough road surfaces, rider control error, etc., may influence the
handling characteristics of your motorcycle. Should this happen, reduce speed and
guide the motorcycle with a relaxed grip to a straightaway position. Do not brake
abruptly or force the handlebars as this may aggravate an unstable condition. New
riders should gain experience under various conditions while driving at moderate speeds.
• Operate your motorcycle defensively. Remember, a motorcycle does not afford the same
protection as an automobile in an accident.
• Wear an approved helmet, clothing and footgear suited to motorcycle riding. Bright or
• light colors are best for greater visibility in traffic especially at night. Avoid loose flowing
garments and scarves.
• The exhaust pipes and mufflers get very hot when the engine is running and remain
too hot to touch for some time after the engine is shut off.
• Wear clothing that will completely cover the legs when riding and avoid
contact with the exhaust system.
53
• Do not allow others, under any circumstances to operate your motorcycle
unless you are certain that they are experienced, licensed riders and are
familiar with the operation of your particular motorcycle.
• When leaving the motorcycle unattended, remove ignition key from switch.
Protect your motorcycle against theft.
• Safe motorcycle operation requires mental awareness and good judgment
combined with a defensive driving attitude. Don’t allow fatigue, alcohol or
drugs to endanger your safety or the safety of others.
• Maintain your motorcycle in proper operating condition in accordance with
the service coupons in this Owner’s Manual. Particularly important to motorcycle
stability is the tire inflation pressure, tread condition, and proper adjustment of
wheel bearings and steering head bearings.
Do not operate motorcycle with loose, worn or damaged steering
system or front or rear suspension system as handling will be adversely
affected. Contact your dealer for repair of steering or suspension system
wear or damage.
• Do not tow a trailer.
• At street intersections, give the right-of-way to the vehicle on your right. Do
not presume too much when you have the right-of-way, the other driver
may not know you have it.
• Always signal when preparing to stop or turn.
• All traffic signs, including those used for the control of traffic at
intersections, should be obeyed promptly and to the letter. SLOW DOWN
signs near schools and CAUTION signs at railroad crossings should
always be observed and your actions governed accordingly.
• Never anticipate a traffic light. When a change is indicated from GO to
STOP (or vice versa) in the traffic control systems at intersections, await
the change.
• When intending to turn to the left, give signal at least 100 feet before
reaching the turning point. Move over to the centerline of the street (unless
local rules require otherwise), slow down passing the intersection of the
street and then turn carefully to the left.
• In turning either right or left, watch for pedestrians as well as vehicles.
• Do not leave the curb or parking area without signaling and seeing that
your way is clear to drive into moving traffic. A moving line of traffic has
the right-of-way.
• See that your license tags are installed in the position specified by law and
that they are clearly visible under all conditions. Keep them clean.
• Ride at a safe speed — a speed consistent with the type of highway you are
on, and always note whether the road is dry, oily, icy or wet. Each varying
condition on the highway means adjusting your speed accordingly.
54
Chapter 13
WARRANTY AGREEMENT
Irbit MotorWorks of America, Inc., (IMWA, Inc.) warrants to the first retail purchaser of the URAL® motorcycle
from an Authorized IMWA Dealer and each subsequent owner that the motorcycle is free from defects in materials
and workmanship for the period stated below.
To Qualify For This Warranty
•
•
The URAL® motorcycle must be purchased from a Dealer within the United States who is authorized by
IMWA, Inc. to sell motorcycles. (See www.imz-ural.com for the authorized IMWA Dealer list)
Prior to delivery to the purchaser, the Dealer who is authorized by IMWA, Inc. to sell motorcycles must perform
set-up and pre-delivery service.
Warranty Time Period
•
•
•
Duration: two (2) years parts and labor.
There is no mileage limitation.
Coverage begins the date the motorcycle is sold to the first retail purchaser and the warranty registration card
is received by IMWA, Inc.
Warranty Coverage
•
•
•
•
IMWA, Inc. will repair or replace, at its options, any part (including parts of the emission control systems) that
is found to be defective in material or workmanship under normal use for the applicable time period.
In cases when warranty repair takes longer than 14 days, the warranty time period (see Warranty Time
Period) is extended for the time period of repair, during which the motorcycle could not been ridden due to
failures.
IMWA, Inc. provides warranty for spare parts for the following period of time starting from the time of purchase
of the parts by a Dealer or retail customer.
1. Engine – 12 months
2. Gearbox – 12 months
3. Final drive – 12 months
4. Alternator – 6 months
5. Electric starter – 6 months
6. Ignition – 6 months
7. The rest of the motorcycle parts and parts assemblies - 30 days
The above applies ONLY in cases when Dealer or retail customer identifies defects before using parts and/or assemblies
or these defects are identified during performance AND provided these parts have been properly installed by IMWA,
Inc. or authorized IMWA Dealer.
IMWA, Inc. will reimburse non-IMWA repair shops performing warranty repair for labor only if all the warranty
processing and approval procedures are completely fulfilled and/or carried out according to IMWA, Inc. guidelines
stated in the Warranty Claim Filing Procedures (see Warranty Claim Filing Procedures).
Warranty Terms – Dealer Demo Bikes
Warranty term for the retail buyer begins on the day that title transfers to the first retail purchaser. Thus, during the
period a Dealer uses a bike for demonstration or show purposes, the warranty will be honored to the Dealer,
provided proper maintenance procedures are followed during the demonstration period. If the Dealer sells the
motorcycle to another Authorized IMWA Dealer, the warranty will continue, and the limited time warranty (described
above) will begin on the day that title transfers to the first retail purchaser.
The exception to the above is if a motorcycle has over 1,500 km on it at the time of transfer to the retail buyer, the
bike remained on the Dealer’s floor for over 12 months from the time of purchase from IMWA, Inc. or if the Dealer
55
has voided the warranty through improper maintenance, usage, modifications, etc. Any failure of the speedometer
assembly on any floor models will require the defective speedometer assembly to be returned to IMWA, Inc. in
Redmond, WA. In any of the above cases, Dealer’s State Law and mileage requirements will determine whether
the sale of a demonstrator motorcycle shall be considered new or used.
Modifications of IMWA, Inc. Limited Warranty for URAL® Motorcycles for
Commercial Uses
All aspects of the normal non-commercial warranty apply except:
1. Parts and labor coverage limited to the first 10,000 km of mileage or one (1) year, which ever comes sooner
(rather than limited mileage).
2. Parts only coverage limited to the second 10,000 km of mileage (up to 20,000 total km) or two (2) years,
whichever comes sooner (rather than unlimited mileage).
3. All scheduled service work outlined in the service coupons at the end of the Owner’s Manual must be performed
at an Authorized URAL® Dealer or a service facility pre-approved in writing by IMWA, Inc.
Note: Copies of all completed service coupons must be sent to IMWA, Inc. within 30 days of completion of each
coupon. Failure to adhere to this requirement will void the warranty.
4. All personnel who operates the motorcycle must sign a statement that they have studied the Owner’s Manual
and have gone through the sidecar motorcycle driving practice before taking the commercially outfitted URAL®
outfit on the public roads.
A copy of a signed and dated statement of completion by each driver and instructor must be sent to IMWA, Inc.
within 30 days of completion of training. Failure to adhere to this requirement will void the warranty.
Warranty Disclaimers
Limitations & Exclusions
Disclaimer of Consequential Damage & Limitation of Implied Warranties
Irbit MotorWorks of America, Inc. disclaims any responsibility for:
•
•
•
•
Loss of time due to warrantable issue
Loss of use of motorcycle
Transportation expenses
Any other incidental or consequential damage (i.e. storage)
Duration of Implied Warranties
Any implied warranties, including the implied warranty of merchantability and fitness for a particular purpose are limited
to the duration of this written warranty.
State Laws May Vary
The previous listed limitations or exclusions may not apply to a motorcycle because of state laws. Some states may not
allow limitations on how long an implied warranty lasts. Some states may not allow exclusion or limitation of incidental or
consequential damages.
56
These Warranties Do Not Cover:
1. Failures or required services that are not due to a defect in material or factory workmanship
2.
•
•
•
•
•
•
•
•
•
•
•
•
Parts or accessories affected or damaged by:
Lack of required maintenance
Owner abuse
Accident and/or collision
Misuse
Normal wear
Neglect
Improper installation
Unsuitable use in an application for which the part was not designed
The incorporation or use of unsuitable attachments or parts
The unauthorized alteration of any part or system
Deterioration from the elements
Failure to follow running-in (break-in) procedure
3. Replacement of expendable maintenance items beyond the first scheduled maintenance, including, but not
limited to:
-spark plugs
-filters
-lubricants
-compliance fittings
-tires (see Owners Manual)
-gaskets
-fuel line
-fuses
-bulbs
4. Paint and/or decal fading, peeling, blistering, chipping or rusting.
5. Use for the following activities; such use will VOID coverage:
•
•
•
•
•
Racing
Competition
Rental or other commercial use
Alteration of engine or drive train
Any operation or use outside of that described in Owner’s Manual
6. Alteration of the odometer so that the actual mileage cannot be determined; alteration will VOID coverage.
7. Use of bike for towing purpose will VOID warranty
57
Dealer and Owner Responsibilities
Dealer Is Responsible For:
•
•
•
•
•
•
•
•
•
Thoroughly check and road test new units before delivery.
Fill out (Please Print!!!), sign and send Warranty Registration and Card of Delivery to IMWA, Inc.
within 3 business days of the sale of Motorcycle.
Accept all eligible motorcycles for warranty service regardless of selling Dealer.
Keep records of all warranty work.
Attend service schools as provided by IMWA, Inc.
Submit warranty claims to IMWA, Inc. IN WRITING within 10 business days of the repair date.
Obtain authorizations for warranty repairs from IMWA, Inc. when estimated cost will exceed $100.00
(see Advance Warranty Authorization).
Send failed parts and/or parts assemblies for an inspection to IMWA, Inc. within 3 (three) business days
upon IMWA’s request at IMWA,Inc. shipping expense.
Provide digital pictures of failed parts and/or parts assemblies immediately upon IMWA’s request.
Customer Is Responsible For:
•
•
Operate and maintain the motorcycle according to the IMWA, Inc. Owner’s Manual and service schedule.
Retain all service records for future reference.
Warranty Claims Filing Procedure
IMWA, Inc. will compensate Dealer for his labor based on authorized procedures only and at the published flat
rate schedule (Appendix B) applied to the Dealer’s approved shop hourly rate.
1. Dealer will fax a warranty parts request to IMWA, Inc. on a Warranty Claim Form (Appendix A) for all
warranty parts.
2. Irbit MotorWorks of America, Inc. will review and when approved, will ship parts within 48 hrs and notify
Dealer if repair will be covered under factory warranty.
3. Dealer must submit claims for labor reimbursement within 10 business days upon receipt of warranty
parts and completion of authorized repair.
4. All submitted claims for labor reimbursement must fall within published flat rate schedule (Appendix B) to
be approved.
5. Parts credit will be issued to the Dealer’s account before the 10th of the month.
6. Warranty repairs estimated to exceed $100.00 in parts and labor must receive prior approval from
IMWA, Inc.
7. Any repair that involves final drive, gearbox or internal invasive examination of engine must
receive prior approval from IMWA, Inc.
Engines, Gearboxes and Final Drives will be replaced on warranty only after the Dealer has
accomplished the following:
1. A qualified IMWA trained technician has completed a thorough external examination, documented
findings and has faxed/e-mailed it to IMWA, Inc. with comments of technician
2. IMWA, Inc. technical staff has reviewed and discussed the problem with the Dealer’s technician
3. IMWA, Inc. issues Return Merchandise Authorization No. and call tag after authorizing return of item and
faxes it to Dealer
58
After IMWA, Inc. inspection of engine or gearbox or final drive:
1. If engine/gearbox/final drive is found to be defective due to factory parts or assembly failure, the
appropriate warranty order will be processed and the flat rate for removal and re-installation of the
engine/gearbox/final drive will be authorized
Failed engines/gearboxes/final drives will be warranted utilizing the following options
at IMWA’s discretion:
• replacement with new engine/gearbox/final drive
• replacement with factory refurbished engine/gearbox/final drive
• repair utilizing new parts or parts assemblies
Factory refurbished engines/gearboxes/final drives are guaranteed to be refurbished to manufacturer’s
specifications.
2. If engine/gearbox/final drive is not defective but inoperable or less than optimal due to lack of easily
diagnosed misalignments and/or normal adjustments or is severely out of adjustment from poor work
or understanding, the warranty claim will be denied and the Dealer will be charged for all shipping and
adjustments at $35.00 IMWA Inc. hourly rate.
Notes:
•
Dealer must notify IMWA, Inc. in writing upon receipt of any motorcycle which may involve over 30 days of
shop time including order and receipt time for parts, service time and delivery time. If Dealer fails to notify
IMWA, Inc. in such a case, Dealer will be solely responsible for any forced motorcycle repurchase that
occurs and may be subject to termination of IMWA, Inc. Dealership.
• IMWA, Inc. reserves the right to perform warranty work at its expense on any motorcycle.
Dealer agrees to properly package and promptly ship any defective item that IMWA, Inc.
requests to be returned.
• Do Not Ship Batteries, Seals, Gaskets or Oils to IMWA, Inc. Dispose of them according to local
laws. Any questions about returning warranty items, contact IMWA, Inc.
• Defective and failed parts that were replaced by warranty are to be held at the Dealership for
90 days.
•
Dealer must send failed parts and/or parts assemblies for an inspection to IMWA, Inc. within 3 (three)
business days upon IMWA’s request at IMWA, Inc. shipping expense.
•
Dealer must provide digital pictures of failed parts and/or parts assemblies immediately upon IMWA’s
request.
Warranty Shipping
All warranty parts are shipped by UPS Ground or Priority Mail (USPS) paid by IMWA, Inc. If Dealer elects to
upgrade to faster shipping service, Dealer agrees to pay full cost of shipping, which will be billed to Dealer’s
account.
59
DISTRIBUTOR’S LIMITED WARRANTY - NOISE CONTROL SYSTEMS
Warranty Time Period
Duration
Time or mileage, whichever occurs first
Time: twelve (12) months
Mileage: 6,000 kilometers (3,728 miles)
Coverage Begins
• the date the vehicle is delivered to the first retail purchaser, or
• the date the vehicle is first placed in service as a demonstrator, lease or company
vehicle prior to the first retail sale.
Warranty
This warranty applies to factory installed noise systems on URAL motorcycles manufactured on or after
May 20, 2003.
Irbit Motorworks of America warrants to the first retail purchaser and each subsequent purchaser that the
motorcycle
• was designed, built and equipped to conform at the time of first retail purchase, with all US
EPA noise emission standards.
• when properly maintained and used, will meet applicable noise emission regulations within the stated
mileage and time periods.
The obligation of Irbit Motorworks of America
To repair or replace, at its option, any part of the exhaust system, or exhaust system’s components, which are
proven to be defective in material or factory workmanship under normal use for the applicable period.
Parts and Labor
No charge for replacement of defective parts.
Your obligation
To have required maintenance works performed in accordance with this manual and Service Coupons. Failure
to have required maintenance performed may result in losing warranty coverage.
Note: The following items are not covered by the Noise Control System Warranty
• Failures which arise as a result of misuse, alterations or accident.
• Replacing, removing or modifying any portion of the Noise Control System (with parts not certified to be
noise legal for street use)
• loss of time, inconvenience, loss of motorcycle use or other consequential damages.
• any motorcycle on which the odometer reading has been changed so that the actual
usage cannot be determined.
RECOMMENDATIONS FOR REQUIRED MAINTENANCE
IT IS RECOMMENDED THAT ANY NOISE SYSTEM MAINTENANCE BE PERFORMED BY AN AUTHORIZED
URAL DEALER USING GENUINE URAL REPLACEMENT PARTS. THE MAINTENANCE, REPLACEMENT OR
REPAIR OF THE NOISE CONTROL SYSTEM MAY BE PERFORMED BY ANY OTHER QUALIFIED SERVICE
OUTLET OR INDIVIDUAL. NON-GENUINE PARTS MAY BE USED ONLY IF SUCH PARTS ARE CERTIFIED
TO COMPLY WITH US ENVIRONMENTAL PROTECTION AGENCY STANDARDS.
60
DISTRIBUTOR’S LIMITED WARRANTY
EMISSION CONTROL SYSTEMS
(49 - State)
Warranty Time Period
Duration
Time or mileage based on engine displacement - whichever occurs first.
Time: five (5) years
Mileage - for motorcycles with engine displacement of 745 cc, 30,000 km (18,642 miles)
Coverage Begins:
• the date the motorcycle is delivered to the first retail purchaser, or
• the date the motorcycle is first placed in service as a demonstrator, rental, lease or company motorcycle
prior to retail sale.
Warranty Coverage
This warranty applies to new Ural motorcycles.
This warranty is given in addition to the Distributor’s Limited Warranty and is the only express emission control
system warranty applicable to Ural motorcycles.
Irbit Motorworks of America warrants to the first retail purchaser and each subsequent purchaser that
• the motorcycle is designed, built and equipped to conform, at the time of sale, with
all US EPA emission standards applicable at the time of manufacture.
• the motorcycle, when properly maintained and used, will meet applicable emission
regulations within the time and mileage periods.
The obligation of Irbit Motorworks of America
To repair or replace, at its option, any part or parts of the emission control systems which are proven to be
defective in material or factory workmanship under normal use for the applicable period.
Parts & Labor
No charge to you.
Your obligation
To have required maintenance performed in accordance with the Service Coupons contained
in this manual. Failure to have required maintenance performed may result in losing coverage under this
warranty.
The following items are not covered by the emission control system warranty:
1. Failures which arise as a result of misuse, alterations, accident or nonperformance of
maintenance as specified in the Owner’s Manual and the Service Coupons.
2. The replacement of parts (such as spark plugs, fuel and oil filters, etc.) used in
required maintenance.
3. Loss of time, inconvenience, loss of motorcycle use or other consequential
damages.
4. Any motorcycle on which the odometer mileage has been changed so that the
mileage cannot be determined.
RECOMMENDATIONS FOR REQUIRED MAINTENANCE
IT IS RECOMMENDED THAT ANY EMISSION SYSTEM MAINTENANCE BE PERFORMED BY AN
61
AUTHORIZED URAL DEALER USING GENUINE URAL REPLACEMENT PARTS. THE MAINTENANCE,
REPLACEMENT OR REPAIR OF THE EMISSION CONTROL SYSTEM MAY BE PERFORMED BY ANY
OTHER QUALIFIED SERVICE OUTLET OR INDIVIDUAL. NON-GENUINE PARTS MAY BE USED ONLY IF
SUCH PARTS ARE CERTIFIED TO COMPLY WITH US ENVIRONMENTAL PROTECTION AGENCY
STANDARDS.
EPA Noise Regulations
EPA noise regulations require that the following statements be included in this Owner’s Manual:
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts
or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of
maintenance, repair or replacement of any device or element of design incorporated into any new vehicle
for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or
(2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED
BELOW:
1. Replacing the muffler (s) and/or the entire exhaust system with parts not certified to be
noise legal for street use.
2. Removing or modifying the muffler internal baffles in any way.
3. Replacing the air intake/cleaner assembly with one not certified to be noise legal for street
use.
4. Modifying the air intake/cleaner assembly in such a way as to make the vehicle no longer
noise legal for street use.
IMPORTANT: If you move from your present address or sell your motorcycle, please fill out and mail
the form at the back of this manual.
REPORTING SAFETY DEFECTS
If you believe that your vehicle has a defect which could cause an accident or could cause injury or death, you
should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying
Irbit Motorworks of America.
If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a
group of vehicles, it may order a recall and remedy campaign. For this reason it is very important for you to
notify Irbit Motorworks of America of any change of address or ownership. There is a form in the back of this
manual. NHTSA cannot become involved in individual problems between you, your dealer or Irbit Motorworks of
America.
To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-800-424-9393 (or (202) 366-0123 in
Washington, DC area) or write to: NHTSA, US Department of Transportation, Washington, DC 20590.
62
Appendix A
Warranty Claim Form
Irbit Motorworks of America, Inc.
Dealer_________________ ______Authorized #___________Date/__/__/__/
Motorcycle Information
VIN # /__/__/__/__/__/__/__/__/__/__/__/__/__/__/__/__/__/
Engine /__/__/__/__/__/__/
Gearbox /__/__/__/__/__/__/ Model ____________ Mileage (km)_________
Owner’s Name______________________ Date of Registration /___/___/___/
Complete
Address___________________________________________________________________________
Comments_________________________________________________________________________________
Service Information
Technician__________________Start Date /___/___/___/ Completion Date /___/___/___/
Diagnosis of Defect________________________________________________________
____________________________________________________________________________________________________________________________________________________________________________________
____________________________________________________________________________________________________________________________________________________________________________________
____________________________________________________________________________________________________________________________________________________________________________________
____________________________________________________________________________________________________________________________________________________________________________________
Part #
Description
Qty
Dlr. Cost
____________________
______________________
______
_________
____________________
______________________
______
_________
____________________
______________________
______
_________
____________________
______________________
______
_________
____________________
______________________
______
_________
____________________
______________________
______
_________
____________________
______________________
______
_________
Parts Total $__________
All warranty parts are shipped using standard UPS ground only.
Flat Rate Schedule: Check the items that pertain to this claim.
1. Engine
1.1 __ 1.4hr
1.2 __ 1.5hr
1.3 __ 2.0hr
1.4 __ 1.5hr
1.5 __ 0.2hr
1.6 __ 0.1hr
6. Sidecar
6.1 ___0.3hr
6.2 ___ 0.1hr
6.3 ___ 0.3hr
6.4 ___0.4hr
1.7 __ 0.1hr
1.8 __ 0.1hr
1.9 __ 0.7hr
1.10 __ 0.4hr
1.11 __ 0.3hr
1.12 __ 0.4hr
1.13 __ 0.3hr
6.5 ___ 0.2hr
6.6 ___ 0.2hr
6.7 ___ 0.4hr
2. Gearbox
2.1 ___ 0.5hr
2.2 ___ 0.1hr
2.3 ___ 0.9hr
2.4 ___ 1.2hr
2.5 ___ 0.4hr
7.Chassis
7.1 ___ 0.3hr
7.2 ___ 0.5hr
7.3 ___ 0.4hr
7.4 ___ 0.3hr
3. Final Drive
3.1 ___ 0.3hr
3.2 ___ 0.4hr
3.3 ___ 0.6hr
3.4 ___ 0.7hr
3.5 ___ 0.7hr
3.6 ___ 0.9hr
7.5
7.6
7.7
7.8
___
___
___
___
0.2hr
0.2hr
0.4hr
0.2hr
3.7 ___ 0.3hr
3.8 ___ 0.2hr
8. Electrical
8.1 ___ 0.6hr
8.2 ___ 0.4hr
8.3 ___ 1.2hr
8.4 ___ 0.6hr
4. Front Fork
4.1 ___0.7hr
4.2 ___ 0.5hr
4.3 ___ 0.5hr
4.4 ___ 0.4hr
8.5
8.6
8.7
8.8
___
___
___
___
0.2hr
0.3hr
0.2hr
0.1hr
5. Wheel & Tire
5.1 ___ 0.2hr
5.2 ___ 0.2hr
5.3 ___ 0.4hr
5.4 ___ 0.3hr
5.5 ___ 0.3hr
5.6 ___ 0.2hr
8.9 ___ 0.3hr
8.10 ___ 0.1hr
8.11 ___ 0.2hr
Labor Information
Flat Rate Hours_______________ Shop Rate $_______________Total $_____________
Dealer Signature_________________________ Date_________
63
Appendix B
Flat Rate Schedule
For warranty repair work on Ural motorcycles
Code
Unit or part
1.0
Engine
Job description
Allowed Time (in Hrs) for IMWA
Authorized Dealers
1.1
Engine removal/mount with gear box
1.4
1.2
Engine disassembly
1.5
1.3
Engine assembly
2.0
1.4
Engine running-in
1.5
1.5
Cylinder head removal/mount
0.2
1.6
Cylinder removal/mount
0.1
1.7
Piston rings removal/mount (1 piston)
0.1
1.8
Piston removal/mount
0.1
1.9
Camshaft removal/mount
0.7
1.10
Exhaust system disconnection/connection to cylinder heads
0.4
1.11
Valve gap adjustment (2 cylinders)
0.3
1.12
Clutch disassembly/assembly (engine removed)
0.4
1.13
Air filter assembly removal/mount
0.3
2.1
Gear box removal/mount (rear wheel and final drive removed)
0.5
2.2
Gear box removal/mount (engine removed)
0.1
2.3
Gear box disassembly
0.9
2.4
Gear box assembly
1.2
2.5
Gear box adjustment
0.4
3.1
Final drive removal/mount (rear wheel removed)
0.3
3.2
Sidecar drive removal/mount (Two-wheel drive mc)
0.4
3.3
Final drive disassembly
0.6
3.4
Final drive disassembly (Two-wheel drive mc)
0.7
3.5
Final drive assembly
0.7
3.6
Final drive assembly (Two-wheel drive mc)
0.9
2.0
3.0
Gear box
Final drive
64
Code
Unit or part
Job description
Allowed Time (in Hrs) for IMWA
Authorized Dealers
3.7
Final drive seal (7205039) replacement
0.3
3.8
Drive shaft removal/mount (final drive removed)
0.2
4.1
Front fork removal/mount
0.7
4.2
Front fork assy disassembly (total)
0.5
4.3
Front fork assembly (total)
0.5
4.4
Front fork bearings adjustment
0.4
5.1
Front wheel removal/mount
0.2
5.2
Rear wheel removal/mount
0.2
5.3
Wheel alignment and balancing
0.4
5.4
Wheel bearing adjustment
0.3
5.5
Tire removal/mount on the rim
0.3
5.6
Brake adjustment ( per wheel)
0.2
6.1
Sidecar removal/mount
0.3
6.2
Sidecar wheel removal/mount
0.1
6.3
Sidecar body removal/mount
0.3
6.4
Sidecar fender removal/mount
0.4
6.5
Shock absorber removal/mount
0.2
6.6
Swing arm removal/mount
0.2
6.7
Rubber member removal/mount
0.4
7.1
Front wheel fender removal/mount
0.3
7.2
Rear wheel fender removal/mount
0.5
7.3
Gas tank removal/mount
0.4
7.4
Knee grips, molding removal/mount
0.3
4.0
5.0
6.0
7.0
Front Fork
Wheel & Tire
Sidecar
Chassis Parts
65
Code
Unit or part
Job description
Allowed Time (in Hrs) for IMWA
Authorized Dealers
7.5
Sidecar wind shield assy removal/mount
0.2
7.6
Shock absorber removal/mount
0.2
7.7
Swing arm removal/ mount
0.4
7.8
Seat removal/mount
0.2
8.1
Wiring diagnosis for short circuit
0.6
8.2
Battery removal/mount
0.4
8.3
Wire harness removal/mount (motorcycle)
1.2
8.4
Wire harness removal/mount (sidecar)
0.6
8.5
Alternator removal/mount
0.2
8.6
Ignition system removal/mount
0.3
8.7
Ignition coil removal/mount
0.2
8.8
Horn removal/mount
0.1
8.9
Ignition lock removal/mount
0.3
8.10
Main switch (RH or LH) removal/mount
0.1
8.11
Any lighting device removal/mount
0.2
8.0
Electrical
66
Chapter 14
SERVICE COUPONS
IMPORTANT
Long and trouble-free enjoyment of your URAL motorcycle depends on following the recommendations outlined throughout the manual and summarized in Chapter 3, together with
regular and proper servicing according to the service coupons provided on the following pages.
Dependable performance may be anticipated if your motorcycle is entrusted for maintenance to an
Authorized IMWA URAL Dealer. A current list of Authorized IMWA URAL dealers may be obtained
from our web site www.imz-ural.com or by sending a self-addressed stamped envelope to:
Irbit Motorworks of America
15411 NE 95th ST.
Redmond, WA 98052
Authorized IMWA URAL Dealers carry spare parts, have special tools for disassembling the motorcycle and employ experienced specialists to service and repair this motorcycle. Make it a practice
to have your motorcycle serviced regularly at the mileage indicated on the Service Coupons.
An owner who is qualified and capable of doing his or her own service work is allowed to do so,
without voiding the manufacturer’s warranty, PROVIDED that you sign the Service Coupon and
date it after the work has been performed.
WARNING: FOR YOUR PERSONAL WELFARE, ALL THE LISTED SERVICE AND MAINTENANCE RECOMMENDATIONS IN THIS MANUAL SHOULD BE FOLLOWED BECAUSE THEY MAY AFFECT THE SAFE OPERATION OF YOUR
MOTORCYCLE.
Note: The performance of new motorcycle initial service is required to keep your new motorcycle warranty in force and to ensure proper emissions system operation.
WARNING: STOP THE ENGINE AND SUPPORT THE MOTORCYCLE SECURELY BEFORE PERFORMING ALL SERVICE PROCEDURES. SERVICE SHOULD BE PERFORMED IN AN ADEQUATELY LIGHTED AND VENTILATED WORK
AREA USING THE PROPER TOOLS. WHEN WORKING ON THE MOTORCYCLE, DO NOT SUPPORT MOTORCYCLE BY
PLACING SUPPORTS UNDER BRAKE PEDAL. DAMAGE TO THE BRAKE SYSTEM COULD OCCUR CAUSING POSSIBLE
MALFUNCTION AND PERSONAL INJURY.
67
SERVICE COUPON NO 1.
500 KM
(To be performed between 400 to 600 km)
Date_______________
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Odometer reading____________
km
Change engine oil and filter.
Change transmission oil.
Change final drive oil.
Check condition of the gasoline petcock, remove any contaminants, replace in-line fuel filters.
Check carburetors while idling for synchronous operation.
Check tension of wheel spokes.
Check fasteners for proper tightening.
Check steering column bearings.
Check alternator bolts
Check brake fluid reservoirs
The maintenance above has been performed as described.
Owner’s Signature
Service Technician’s Signature
SERVICE COUPON NO 2.
2,500 KM
(To be performed between 2,400 to 2,600 km)
Date
1.
2.
3.
4.
5.
6.
7.
Odometer reading
Change engine oil and filter. (See Lubrication List, chapter 11)
Check final drive oil level.
Inspect air filter element.
Check fasteners for proper tightening.
Check steering column bearings.
Check all wheels for correct bearing adjustment.
Check brake fluid reservoirs.
The maintenance above has been performed as described.
Owner’s Signature
Service Technician’s Signature
68
km
SERVICE COUPON NO. 3. 5,000 KM
(To be performed between 4,900 to 5,100 km)
Date
Odometer reading
1.
2.
3.
4.
5.
6.
7.
Change engine oil and filter. (See Lubrication List, chapter 11)
Check transmission oil level.
Check final drive oil level.
Inspect air filter element.
Check condition of the gasoline petcock, remove any contaminants, replace in-line fuel filters
Check carburetors while idling for synchronous operation.
Check :
A
Adjustment of steering column bearings.
B
Tension of wheel spokes
8.
Lubricate:
A
Lever pins, thimbles of clutch cable
B
Hinges of the foot brake pedal shaft and linkage.
9.
10.
11.
12.
km.
Check condition and action of brakes.
Check tires for tread depth greater than 3/32”
Check fasteners for proper tightening.
Check brake fluid reservoirs.
The maintenance above has been performed as described.
Owner’s Signature
Service Technician’s Signature
SERVICE COUPON NO. 4. 7,500 KM
(To be performed between 7,400 to 7,600 km)
Date
1.
2.
3.
4.
5.
6.
7.
Odometer reading
Change engine oil. (See Lubrication List, chapter 11)
Check final drive oil level.
Inspect air filter element.
Check fasteners for proper tightening.
Check steering column bearings.
Check adjustment of wheel bearings.
Check brake fluid reservoirs.
The maintenance above has been performed as described.
Owner’s Signature
Service Technician’s Signature
69
km.
SERVICE COUPON NO. 5. 10,000 KM
(To be performed between 9,900 to 10,100 km)
Date
Odometer reading
km.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Change engine oil and filter. (See Lubrication List, chapter 11)
Change transmission oil. (See Lubrication List, chapter 11)
Change final drive oil. (See Lubrication List, chapter 11)
Inspect air filter element.
Torque cylinder head stud nuts.
Adjust valve tappet clearance.
Change oil in front fork shock absorbers (on telescopic fork models)
Replace the spark plugs and inspect ignition leads.
Replace in-line fuel filters.
Check:
A
Carburetors while idling for synchronous operation
B
Check steering column bearings & adjust if required.
C
The condition and action of the brakes, lubricate the brake shoe fulcrum pins and cams.
D
The tension of wheel spokes. Adjust if necessary.
E
Electric wiring. Tighten connections if required.
F
Fasteners for proper tightening.
11.
12.
Re-pack the grease in wheel bearings, adjust the bearings.
Lubricate:
A
Foot brake pedal shaft
B
Hinges of foot brake pedal shaft and linkage.
C
Lever pins and thimbles of clutch control cable.
D
Drive shaft splines
Check battery electrolyte level.
Check tires, tread depth greater than 3/32”
Check the timing.
Check brake fluid reservoirs.
13.
14.
14.
15.
The maintenance above has been performed as described.
Owner’s Signature
Service Technician’s Signature
70
SERVICE COUPON NO. 6. 12,500 KM
(To be performed between 12,400 to 12,600 km
Date
1.
2.
3.
4.
5.
Odometer reading
km
Change engine oil. (See Lubrication List, chapter 11)
Check final drive oil level.
Inspect air filter element.
Check fasteners for proper tightening.
Check adjustment of wheel bearings.
The maintenance above has been performed as described.
Owner’s Signature
Service Technician’s Signature
SERVICE COUPON NO. 7 15,000 KM
(To be performed between 14,900 to 15,100 km)
Date
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Odometer reading
Change engine oil and filter. (See lubrication, chapter 11)
Change transmission oil. (See lubrication, chapter 11)
Inspect air filter element
Check carburetors while idling for synchronous operation.
Check adjustment of steering column bearings.
Lubricate:
A
Lever pins
B
Hinges of the foot brake pedal shaft and linkage
Check condition and action of brakes
Check adjustment of wheel bearings.
Check tires for tread depth greater than 3/32".
Check fasteners for proper tightening.
Check brake fluid reservoirs.
The maintenance above has been performed as described.
Owner’s Signature
Service Technician’s Signature
71
km
SERVICE COUPON NO. 8. 17,500 KM
(To be carried out within 17,400 to 17,600 km
Date
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Odometer reading
Clean the air filter, .
Change oil in the engine and transmission. (See Lubrication List, chapter 11)
Check condition of the gasoline petcock, remove any contaminants, clean and blow out.
Check carburetors while idling for synchronous operation.
Check final drive gear oil level. (See Lubrication List, chapter 11)
Lubricate foot brake pedal shaft.
Check fasteners for proper tightening.
Adjust steering column bearings.
Check battery electrolyte level and fluid level.
Check air gap in electronic ignition between pickup and rotor (0.010 in).
The maintenance above has been performed as described.
Owner’s Signature
Service Technician’s Signature
72
km
SERVICE COUPON NO. 9. 20,000 KM
(To be performed between 19,900 to 20,100 km)
Date
Odometer reading
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Change engine oil and filter. (See Lubrication List, chapter 11)
Change transmission oil. (See Lubrication List, chapter 11)
Change final drive oil. (See Lubrication List, chapter 11)
Inspect air filter element.
Torque cylinder head stud nuts.
Adjust valve tappet clearance.
Change oil in front fork shock absorbers (on telescopic fork models)
Replace the spark plugs and inspect ignition leads.
Replace in-line fuel filters.
Check:
A
Carburetors while idling for synchronous operation
B
Check steering column bearings & adjust if required.
C
The condition and action of the brakes.
D
The tension of wheel spokes. Adjust if necessary.
E
Electric wiring. Tighten connections if required.
F
Fasteners for proper tightening.
11.
12.
Repack the grease in wheel bearings, adjust the bearings.
Lubricate:
A
Foot brake pedal shaft
B
Hinges of foot brake pedal shaft and linkage.
C
Lever pins and thimbles of clutch and front wheel brake control cables.
D
Drive shaft splines
Check battery electrolyte level.
Check tires, tread depth greater than 3/32”
Check the timing.
Check brake fluid reservoirs.
13.
14.
15.
16.
The maintenance above has been performed as described.
Owner’s Signature
Service Technician’s Signature
73
km.
SERVICE COUPON NO. 10. 22,500 KM
(To be performed between 22,400 to 22,600 km
Date
1.
2.
3.
4.
5.
6.
Odometer reading
km
Change engine oil. (See Lubrication List, chapter 11)
Check final drive oil level.
Inspect air filter element.
Check fasteners for proper tightening.
Check steering column bearings.
Check adjustment of wheel bearings.
The maintenance above has been performed as described.
Owner’s Signature
Service Technician’s Signature
SERVICE COUPON NO. 11. 25,000 KM
(To be performed between 24,900 to 25,100 km)
Date
Odometer reading
1.
2.
3.
4.
5.
Change engine oil and filter. (See Lubrication List, chapter 11)
Change transmission oil. (See Lubrication List, chapter 11)
Inspect air filter element.
Check carburetors while idling for synchronous operation.
Check:
A
Adjustment of steering column bearings.
B
Tension of wheel spokes
6.
Lubricate:
A
Lever pins
B
Foot brake pedal shaft
C
Hinges of the foot brake pedal shaft and linkage.
7.
8.
9.
10.
Check condition and action of brakes
Check tires for tread depth greater than 3/32”
Check fasteners for proper tightening.
Check brake fluid reservoirs.
The maintenance above has been performed as described.
Owner’s Signature
Service Technician’s Signature
74
km.
SERVICE COUPON NO 12.
27,500 KM
(To be performed between 27,400 to 27,600 km)
Date
1.
2.
3.
4.
5.
6.
Odometer reading
Change engine oil. (See Lubrication List, chapter 11)
Check final drive oil level.
Inspect air filter element.
Check fasteners for proper tightening.
Check steering column bearings.
Check adjustment of wheel bearings.
The maintenance above has been performed as described.
Owner’s Signature
Service Technician’s Signature
75
km
SERVICE COUPON NO. 13. 30,000 KM
(To be performed between 29,900 to 30,100 km)
Date
Odometer reading
km.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Change engine oil and filter. (See Lubrication List, chapter 11)
Change transmission oil. (See Lubrication List, chapter 11)
Change final drive oil. (See Lubrication List, chapter 11)
Inspect air filter element.
Torque cylinder head stud nuts.
Adjust valve tappet clearance.
Change oil in front fork shock absorbers (on telescopic fork models)
Replace the spark plugs and inspect ignition leads.
Replace in-line fuel filters.
Check:
A
Carburetors while idling for synchronous operation
B
Check steering column bearings & adjust if required.
C
The condition and action of the brakes, lubricate the brake shoe fulcrum pins and cams.
D
The tension of wheel spokes. Adjust if necessary.
E
Electric wiring. Tighten connections if required.
F
Fasteners for proper tightening.
11.
12.
Repack the grease in wheel bearings, adjust the bearings.
Lubricate:
A
Foot brake pedal shaft
B
Hinges of foot brake pedal shaft and linkage.
C
Lever pins and thimbles of clutch and front wheel brake control cables.
D
Drive shaft splines
Check battery electrolyte level.
Check tires, tread depth greater than 3/32”
Check the timing.
Check brake fluid reservoirs.
13.
14.
15.
16.
The maintenance above has been performed as described.
Owner’s Signature
Service Technician’s Signature
76
NEW ADDRESS FORM
If you move, please fill out this form and mail to the address below. This will insure that you continue to receive all correspondence from Irbit Motorworks of America.
VEHICLE IDENTIFICATION NUMBER
OWNER’S NAME _____________________________________________
OLD ADDRESS ______________________________ APT. NO. _______
CITY ________________ STATE ____________ ZIP CODE _________
MY NEW ADDRESS IS:
NEW ADDRESS ____________________________ APT. NO. ________
CITY _______________ STATE _____________ ZIP CODE _________
Send this form to:
Irbit Motorworks of America,
15411 NE 95th ST.
Redmond, WA 98052
or fax to:
(425) 696 - 0834
77
NEW OWNER FORM
If you purchase a Ural Motorcycle from somebody other than a dealer, please fill out this form and
mail to the address below. This will insure that you receive all correspondence from Irbit Motorworks of America
VEHICLE IDENTIFICATION NUMBER
NEW OWNER’S NAME _____________________________________________
ADDRESS ______________________________ APT. NO. _______
CITY ________________ STATE ____________ ZIP CODE _________
DATE OF SALE ________________
MO / DAY / YEAR
Purchased From ___________________________________________________
City _____________________State ____________ Zip Code _______________
Send this form to:
Irbit Motorworks of America,
15411 NE 95th ST.
Redmond, WA 98052
or fax to:
(425) 696 - 0834
78
URAL - STARTING & RUNNING TIPS
Starting the Engine
1. Open carburetor enricheners on both carburetors (pull lever out) if temperature is below 50 degrees.
2. Make sure fuel petcock is open “ON” or on reserve “RES.” Fuel petcock handle should be in 6 or
12 o’clock position.
3. Ignition “RUN,” “KILL,” switch set to “RUN” (down), gearbox in “NEUTRAL,” master battery
switch (under seat) “ON.”
4. Push starter button until engine fires,
OR…
5. With foot on kick-starter lever, push foot down swiftly and hard open the throttle grip slightly.
Repeat until engine fires (usually 2 or 3 kicks). Turn OFF enricheners.
6. Let the engine warm up for 1-3 minutes, depending on the temperature.
7. After the engine has warmed up, operate the motorcycle under moderate loads and speeds for
several miles until the oil has circulated well and the engine and gearbox are functioning smoothly.
TroubleShooting
If engine does not start with above method, the problem(s) may be one or more of the following:
1. Engine is “flooded,” i.e.; the spark plugs have been “fouled” by too much throttle ( and fuel ) and will
not spark.
Correction: Flooding is corrected by removing the spark plugs and drying them.
2. Too little fuel is getting to the engine due to low fuel in tank and/or plugged fuel lines or fuel petcock.
Correction: Clogged fuel lines or filter are corrected by blowing through fuel lines from carburetor end to
remove any debris from lines. Fuel petcock filter can be cleaned by removing and cleaning.
3. Little or no spark is available to the engine due to a low battery, (dim headlight), or loose ignition
wires.
Correction: Dead battery is corrected by charging battery, loose or broken ignition wires are corrected by
replacing broken wire(s) or by reconnecting wires at either the spark plug cap, the ignition module, or at the
ignition coil under the front cover of the engine.
*4. Not enough compression in the cylinders due to excessive wear or incorrect adjustment
of valve(s).
* item 4 above requires the attention of a qualified mechanic at your URAL dealer.
79
Pre-Trip Check List
1.
2.
3.
4.
5.
6.
Check all lights and the horn for proper operation.
Check the brake and clutch levers and/or pedals.
Make sure all wheels and the final drive assemblies are securely fastened .
Check the carburetor flanges and air filter ducts for integrity and proper alignment.
Check the tire tread depth - should be greater than 1/8 inch.
Check the sidecar attachment mounts – all mounts should be securely tightened.
Gasoline level in the fully filled tank should be 10 - 15 mm / ½ - ¾ in. below the lower edge of the
tank filler. Do not overfill the tank.
See that the oil level in the engine crankcase is not higher than the top and not lower than the
bottom marks on the dipstick with the filler plug undone. (See chapter 4 Lubrication System)
Here Are Some Helpful Publications To Help You With Your
New Ural
Learning to Ride The Ural With Sidecar Accessory
Available through the Whitehorse Press
www.whitehorsepress.com
Available through Mike Weaver
[email protected]
www.molotovmotors.com
Weav’s Useful Information and Technical Guide to Antique Russian Motorcycles and Sidecars